Engine control device and methods thereof

ABSTRACT

An engine control device may comprise a processor and a memory. The engine control device may be configured to modify a fuel flow based on a density of the fuel proximate a fuel nozzle. The engine control device may include a densimeter embedded in, or disposed proximate, the engine control device. The engine control device may include a temperature sensor embedded in, or disposed proximate, the engine control device. The engine control device may be electrically coupled to a fuel valve and/or configured to modulate the fuel valve based on a density of the fuel at the fuel valve.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of, and claims priority to, and thebenefit of Non-Provisional application Ser. No. 16/786,758, filed Feb.10, 2020, for ENGINE CONTROL DEVICE AND METHODS THEREOF, which isincorporated in its entirety by reference herein for all purposes.

STATEMENT OF GOVERNMENT INTEREST

This invention was made with Government support awarded by the UnitedStates. The Government has certain rights in this invention.

FIELD

The present disclosure relates to gas turbine engines, and, morespecifically, to engine control devices and methods thereof for a gasturbine engine.

BACKGROUND

A gas turbine engine typically includes a fan section, a compressorsection, a combustor section, and a turbine section. In general, duringoperation, air is pressurized in the fan and compressor sections and ismixed with fuel and burned in the combustor section to generate hotcombustion gases. The hot combustion gases flow through the turbinesection, which extracts energy from the hot combustion gases to powerthe compressor section and other gas turbine engine loads. Gas turbineengines may include fuel having variation in fuel density from batch tobatch. Variation in fuel density may contribute to fuel flow inaccuracyin metering fuel to the combustor section.

SUMMARY

An engine control device is disclosed herein. The engine control devicemay comprise: a housing; a fluid conduit disposed through the housing,the fluid conduit configured to receive fuel during operation of theengine control device; and a densimeter operably coupled to the fluidconduit, the densimeter being disposed in the housing and configured todetermine a density of the fuel.

In various embodiments, the engine control device is configured tocontrol a fuel flow to a fuel nozzle based on measurements from thedensimeter. The engine control device may further comprise: atemperature sensor operably coupled to the fluid conduit to measure atemperature of the fuel; a processor; and a non-transitory computerreadable storage medium in electronic communication with the processor,the non-transitory computer readable storage medium having instructionsstored thereon that, in response to execution by the processor cause theprocessor to perform operations comprising: detecting, by the processor,a first temperature of the fuel flowing through the fluid conduit fromthe temperature sensor; detecting, by the processor, a first density ofthe fuel at the first temperature from the densimeter; calculating, bythe processor, a second density at a second temperature; and modifying,by the processor, a fuel flow to a fuel nozzle of a gas-turbine enginebased on the second density. The operations may further comprisedetecting, by the processor, the second temperature of the fuel at afuel valve assembly. The operations may further comprise detecting, bythe processor, the second temperature at the fuel valve assembly. Thefluid conduit may include an inlet port and an outlet port. The inletport may be disposed at a first end of the fluid conduit and the outletport may be disposed at a second end of the fluid conduit.

A fuel flow control system for a gas turbine engine is disclosed herein.The fuel flow control system may comprise: a fuel supply; a fluidconduit in fluid communication with the fuel supply; an engine controldevice in fluid communication with the fuel supply; a densimeteroperably coupled to the fluid conduit; a first temperature sensoroperably coupled to the fluid conduit; a fuel nozzle in fluidcommunication with the fuel supply; and a second temperature sensordisposed between the fuel nozzle and the fuel supply.

In various embodiments, the engine control device may be configured tocontrol a fuel flow to the fuel nozzle based on measurements from thedensimeter, the first temperature sensor, and the second temperaturesensor. The densimeter may be embedded in the engine control device. Thefluid conduit may be disposed through the engine control device. Thefluid conduit may be disposed between the fuel supply and the enginecontrol device. The densimeter may be electrically coupled to the enginecontrol device. The fuel flow control system may further comprise a fuelvalve assembly, wherein the second temperature sensor is disposed in thefuel valve assembly. The fuel valve assembly may include a fuel valveelectrically coupled to the engine control device. The engine controldevice may be configured to modulate the fuel valve based onmeasurements of the first temperature sensor, the second temperaturesensor, and the densimeter. Fuel from the fuel supply may be configuredto cool the engine control device during operation of the gas turbineengine.

A method of controlling a fuel flow in a gas turbine engine, the methodcomprising: measuring a first fuel temperature at a first location;measuring a first fuel density at the first location; measuring a secondfuel temperature at a second location; calculating a second fuel densityat the second location based on the second fuel temperature, the firstfuel temperature, and the first fuel density; and modifying the fuelflow at the second location in response to calculating the second fueldensity.

The foregoing features and elements may be combined in variouscombinations without exclusivity, unless expressly indicated otherwise.These features and elements as well as the operation thereof will becomemore apparent in light of the following description and the accompanyingdrawings. It should be understood, however, the following descriptionand drawings are intended to be exemplary in nature and non-limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter of the present disclosure is particularly pointed outand distinctly claimed in the concluding portion of the specification. Amore complete understanding of the present disclosure, however, may bestbe obtained by referring to the detailed description and claims whenconsidered in connection with the figures, wherein like numerals denotelike elements.

FIG. 1 illustrates a cross-sectional view of an exemplary gas turbineengine, in accordance with various embodiments;

FIG. 2 illustrates a schematic view of a fuel flow control system, inaccordance with various embodiments;

FIG. 3 illustrates a schematic view of a fuel flow control system, inaccordance with various embodiments; and

FIG. 4 illustrates a method of controlling fuel flow, in accordance withvarious embodiments.

DETAILED DESCRIPTION

The detailed description of exemplary embodiments herein makes referenceto the accompanying drawings, which show exemplary embodiments by way ofillustration. While these exemplary embodiments are described insufficient detail to enable those skilled in the art to practice theexemplary embodiments of the disclosure, it should be understood thatother embodiments may be realized and that logical changes andadaptations in design and construction may be made in accordance withthis disclosure and the teachings herein. Thus, the detailed descriptionherein is presented for purposes of illustration only and notlimitation. The steps recited in any of the method or processdescriptions may be executed in any order and are not necessarilylimited to the order presented.

Furthermore, any reference to singular includes plural embodiments, andany reference to more than one component or step may include a singularembodiment or step. Also, any reference to attached, fixed, connected orthe like may include permanent, removable, temporary, partial, fulland/or any other possible attachment option. Additionally, any referenceto without contact (or similar phrases) may also include reduced contactor minimal contact. Surface cross hatching lines may be used throughoutthe figures to denote different parts but not necessarily to denote thesame or different materials.

Throughout the present disclosure, like reference numbers denote likeelements. Accordingly, elements with like element numbering may be shownin the figures, but may not necessarily be repeated herein for the sakeof clarity.

A fuel flow control system is disclosed herein. The fuel flow controlsystem may comprise an engine control device configured to control afuel flow of a gas-turbine engine. The engine control device may includea conduit disposed therethrough. Fuel may flow through the conduitduring normal operation of the gas-turbine engine. The conduit may becoupled to a densimeter. The densimeter may be configured to measure adensity of the fuel flowing therethrough. The densimeter may be disposedin the engine control device or proximate the engine control device. Thefuel flow control system may further comprise a fuel valve assembly. Thefuel valve assembly may comprise a fuel valve and a fuel exittemperature sensor in electrical communication with the engine controldevice. The engine control device may be configured to control the fuelflow at the fuel valve in response to measuring a fuel temperature andfuel density at or proximate the engine control device and correctingfor fuel temperature at the fuel valve assembly. In this regard, thefuel flow control system may accurately enable better control of fuelburn and/or thrust relative to typical fuel flow control systems, inaccordance with various embodiments.

In various embodiments and with reference to FIG. 1 , a gas turbineengine 20 is provided. Gas turbine engine 20 may generally include a fansection 22, a compressor section 24, a combustor section 26, and aturbine section 28. In operation, fan section 22 drives fluid (e.g.,air) along a bypass flow-path B, while compressor section 24 drivesfluid along a core flow-path C for compression and communication intocombustor section 26 and then expansion through turbine section 28.Although gas turbine engine 20 is depicted as a turbofan gas turbineengine herein, it should be understood that the concepts describedherein are not limited to use with turbofans as the teachings may beapplied to other types of turbine engines.

Gas turbine engine 20 may generally comprise a low speed spool 30 and ahigh speed spool 32 mounted concentrically, via bearing systems 38, forrotation about for rotation about engine central longitudinal axis A-A′and relative to an engine static structure 36. It should be understoodthat various bearing systems 38 at various locations may alternativelyor additionally be provided, including for example, bearing system 38,bearing system 38-1, and bearing system 38-2. Engine centrallongitudinal axis A-A′ is oriented in the z direction on the providedxyz axes. The z direction on the provided xyz axes refers to the axialdirection. As used herein, the term “radially” refer to directionstowards and away from engine central longitudinal axis A-A′ and thez-axis. As used herein, the terms “circumferential” and“circumferentially” refer to directions about central longitudinal axisA-A′ and the z-axis.

Low speed spool 30 may generally comprise an inner shaft 40 thatinterconnects a fan 42, a low pressure compressor 44, and a low pressureturbine 46. Inner shaft 40 may be connected to fan 42 through a gearedarchitecture 48 that can drive fan 42 at a lower speed than low speedspool 30. Geared architecture 48 may comprise a gear assembly 60enclosed within a gear housing 62. Gear assembly 60 couples inner shaft40 to a rotating fan structure. High speed spool 32 may comprise anouter shaft 50 that interconnects a high pressure compressor 52 and highpressure turbine 54. A combustor 56 may be located between high pressurecompressor 52 and high pressure turbine 54. A mid-turbine frame 57 ofengine static structure 36 may be located generally between highpressure turbine 54 and low pressure turbine 46. Mid-turbine frame 57may support one or more bearing systems 38 in turbine section 28. Innershaft 40 and outer shaft 50 may be concentric and rotate via bearingsystems 38 about engine central longitudinal axis A-A′, which iscollinear with their longitudinal axes. As used herein, a “highpressure” compressor or turbine experiences a higher pressure than acorresponding “low pressure” compressor or turbine. The airflow in coreflow-path C may be compressed by low pressure compressor 44 and highpressure compressor 52, mixed and burned with fuel in combustor 56, thenexpanded over high pressure turbine 54 and low pressure turbine 46.Turbines 46, 54 rotationally drive the respective low speed spool 30 andhigh speed spool 32 in response to the expansion.

The compressor section 24, the combustor section 26, and the turbinesection 28 are generally referred to as the engine core. Air is drawninto gas turbine engine 20 through fan 42. Air exiting fan 42 may bedivided between core flow-path C and bypass flow-path B. The airflow inbypass flow-path B may be utilized for multiple purposes including, forexample, cooling and pressurization.

In various embodiments, the gas turbine engine 20 further comprises anengine control device 110. The engine control device 110 may comprise afull authority digital engine control (FADEC) system or an electronicengine control (EEC) system, or the like. The engine control device 110may be mounted to a fan section 22, any engine environment between −70°F. (−57° C.) degree F. and 190° F. (88° C.), or the like. The enginecontrol device 110 may be configured to control and/or meter a flowvolume, a flow rate, or the like of the fuel at a fuel valve in fluidcommunication with a fuel nozzle in combustor section 26.

Referring now to FIG. 2 , a fuel flow control system 100, in accordancewith various embodiments, is illustrated. The fuel flow control system100 includes an engine control device 110 and a fuel valve assembly 120.The engine control device 110 may comprise a processor 112, a memory114, a temperature sensor 116, and a densimeter 118. The processor 112may include one or more processors and/or one or more non-transitorymemories and be capable of implementing logic. Each processor can be ageneral purpose processor, a digital signal processor (DSP), anapplication specific integrated circuit (ASIC), a field programmablegate array (FPGA) or other programmable logic device, discrete gate ortransistor logic, discrete hardware components, or any combinationthereof. Memory 114 may comprise an article of manufacture including anon-transitory computer-readable storage medium having instructionsstored thereon that, in response to execution by the computing device(e.g., processor 112), cause the computing device to perform variousmethods, as discussed further herein.

In various embodiments, the processor 112 may comprise a processorconfigured to implement various logical operations in response toexecution of instructions, for example, instructions stored on anon-transitory computer-readable medium. As used herein, the term“non-transitory” is to be understood to remove only propagatingtransitory signals per se from the claim scope and does not relinquishrights to all standard computer-readable media that are not onlypropagating transitory signals per se.

In various embodiments, the processor 112 may be configured to controlthe fuel flow control system 100. For example, processor 112 may beconfigured to transfer a control signal to the fuel valve assembly 120to control a fuel volume, fuel flow rate, or the like at fuel valveassembly 120.

In various embodiments, the temperature sensor 116 may include one ormore of a negative temperature coefficient (NTC) thermistor, aresistance temperature detector (RTD), a thermocouple, a semi-conductorbased sensor, or the like. In various embodiments, the densimeter 118may include one or more of a Coriolis densimeter, an ultrasounddensimeter, a microwave densimeter, a gravitic densimeter, or the like.

In various embodiments, the engine control device 110 may furthercomprise a fluid conduit 105 and a housing 111. The fluid conduit 105may be disposed through the housing 111. The temperature sensor 116and/or the densimeter 118 may be embedded in the housing 111. The fluidconduit 105 may be configured to allow fuel flow therethrough. The fuelflowing through fluid conduit 105 may be configured to cool the enginecontrol device 110 during operation of gas turbine engine 20 from FIG. 1. The fluid conduit 105 may include an inlet port 102 and an outlet port104. The inlet port 102 may be disposed at a first end of the housing111 of engine control device 110. The outlet port 104 may be disposed ata second end of the housing 111 of the engine control device 110. Thetemperature sensor 116 and the densimeter 118 may be operably coupled tothe fluid conduit 105. For example, the temperature sensor 116 may beconfigured to measure a fuel temperature of the fuel flowing throughfluid conduit 105 during normal operation. Similarly, the densimeter 118may be configured to measure and/or calculate a density of the fuelduring normal operation. In various embodiments, the densimeter 118and/or the temperature sensor 116 are embedded in engine control device110. In this regard, there will be no (or reduced) external electricalconnections and/or fewer components in a fuel flow control system 100.

In various embodiments, the engine control device 110 is electricallycoupled to a fuel exit temperature sensor 122 and a fuel valve 124 ofthe fuel valve assembly 120. The fuel valve assembly 120 may be disposedin combustor section 56 of FIG. 1 proximate fuel nozzles, or the like.Fuel exit temperature sensor 122 may be configured to measure a fueltemperature at fuel valve assembly 120 and communicate the fueltemperature at fuel valve assembly 120 to the engine control device 110.The engine control device 110 may be configured to send a control signalto fuel valve 124 to meter the flow of fuel at a desired rate inresponse to measuring a density and temperature of the fuel in theengine control device 110 and correcting for a density of fuel at thefuel valve assembly based on the fuel temperature at the fuel valveassembly 120. In this regard, a fuel flow rate may be modified based ona density of fuel and/or provide more accurate fuel flow for bettercontrol of fuel burn and/or thrust.

In various embodiments, the fuel flow control system 100 may furthercomprise a fuel supply 130 and a fuel nozzle 140. The fuel supply 130may be in fluid communication with the engine control device 110 and thefuel valve assembly 120. For example, a fluid conduit 132 may extendfrom the fuel supply 130 to the inlet port 102 of the engine controldevice 110. Fluid conduit 132 may be coupled to the inlet port 102 byany method known in the art, such as via adapters, fittings, nuts, orthe like. Similarly, a fluid conduit 134 may extend from fuel supply 130to the fuel valve assembly 120. Fuel valve 124 may meter the flow offuel from fuel supply 130 to fuel nozzle 140. In various embodiments,fuel valve 124 may comprise a fuel modulating valve, a fuel modulatingunit, or the like.

Referring now to FIG. 3 , a fuel flow control system 200, in accordancewith various embodiments, is illustrated. The fuel flow control system200 includes an engine control device 210 and a fuel valve assembly 120.The engine control device 210 may comprise a processor 212 and a memory214. The processor 212 may be in accordance with processor 112. Memory214 may be in accordance with memory 114.

In various embodiments, the processor 212 may be configured to controlthe fuel flow control system 200. For example, processor 212 may beconfigured to transfer a control signal to the fuel valve assembly 220to control a fuel volume, fuel flow rate, or the like at fuel valveassembly 220.

In various embodiments, the engine control device 210 may furthercomprise a fluid conduit 205 disposed therethrough. The fluid conduit205 may be configured to allow fuel flow therethrough. The fuel flowingthrough fluid conduit 205 may be configured to cool the engine controldevice 210 during operation of gas turbine engine 20 from FIG. 1 . Thefluid conduit 205 may include an inlet port 202 and an outlet port 204.

In various embodiments, the fuel flow control system 200 may furthercomprise a temperature sensor 216 and a densimeter 218 disposed proximalthe engine control device 210. The temperature sensor 216 and thedensimeter 218 may be operably coupled to the fluid conduit 205 externalto the engine control device 210. The densimeter 218 and the temperaturesensor 216 may be electrically coupled to the engine control device 210.For example, the temperature sensor 216 may be configured to measure afuel temperature of the fuel flowing through fluid conduit 205 duringnormal operation. Similarly, the densimeter 118 may be configured tomeasure and/or calculate a density of the fuel during normal operation.The density data and temperature data of the fuel proximate the enginecontrol device 210 may be provided to the engine control device 210.

In various embodiments, the engine control device 210 is electricallycoupled to a fuel exit temperature sensor 222 and a fuel valve 224 ofthe fuel valve assembly 220. The fuel valve assembly 220 may be disposedin combustor section 56 of FIG. 1 proximate fuel nozzles, or the like.Fuel exit temperature sensor 222 may be configured to measure a fueltemperature at fuel valve assembly 220 and communicate the fueltemperature at fuel valve assembly 220 to the engine control device 210.The engine control device 210 may be configured to send a control signalto fuel valve 224 to meter the flow of fuel at a desired rate inresponse to measuring a density and temperature of the fuel in theengine control device 210 and correcting for a density of fuel at thefuel valve assembly based on the fuel temperature at the fuel valveassembly 220. In this regard, a fuel flow rate may be modified based ona density of fuel measured by the densimeter 218 and/or provide moreaccurate fuel flow for better control of fuel burn and/or thrust.

In various embodiments, the fuel flow control system 200 may furthercomprise a fuel supply 230 and a fuel nozzle 240. The fuel supply 230may be in fluid communication with the engine control device 210 and thefuel valve assembly 220. Fuel valve 224 may meter the flow of fuel fromfuel supply 230 to fuel nozzle 240. In various embodiments, fuel valve224 may comprise a fuel modulating valve, a fuel modulating unit, or thelike.

Referring now to FIG. 4 , a method 400 of controlling a fuel flow of agas turbine engine is illustrated, in accordance with variousembodiments. The method 400 comprises measuring a first fuel temperatureof a fuel (step 402). In various embodiments, the first fuel temperaturemay be measured using a first temperature sensor disposed proximate anengine control device. In various embodiments, the first fueltemperature may be measured using a first temperature sensor disposed inan engine control device. The fuel may be configured to flow through theengine control device. The engine control device may be in fluidcommunication with a fuel supply. The fuel may be configured to cool theengine control device.

In various embodiments, the method 400 may further comprise measuring afirst density of the fuel at the first fuel temperature (step 404). Thefirst density may be measured using a densimeter. The densimeter may bedisposed proximate the engine control device, or the densimeter may beembedded in the engine control device. The method 400 may furthercomprise measuring a second fuel temperature of the fuel (step 406). Thesecond temperature of the fuel may be measured proximate a fuel nozzlein a combustor section. For example, the second temperature may bemeasured at a fuel valve assembly in fluid communication with the fuelnozzle. The second temperature may be measured via a second temperaturesensor disposed in the fuel valve assembly.

In various embodiments, the method may further comprise calculating asecond density of the fuel at the second fuel temperature (step 408).Density is inversely proportional to temperature. As such, the seconddensity of the fuel at the second fuel temperature may be calculatedbased on the first density measured at the first temperature. In thisregard, a second density at the fuel valve assembly may be determinedbased on the first density, the first temperature, and the secondtemperature.

Benefits, other advantages, and solutions to problems have beendescribed herein with regard to specific embodiments. Furthermore, theconnecting lines shown in the various figures contained herein areintended to represent exemplary functional relationships and/or physicalcouplings between the various elements. It should be noted that manyalternative or additional functional relationships or physicalconnections may be present in a practical system. However, the benefits,advantages, solutions to problems, and any elements that may cause anybenefit, advantage, or solution to occur or become more pronounced arenot to be construed as critical, required, or essential features orelements of the disclosures. The scope of the disclosures is accordinglyto be limited by nothing other than the appended claims, in whichreference to an element in the singular is not intended to mean “one andonly one” unless explicitly so stated, but rather “one or more.”Moreover, where a phrase similar to “at least one of A, B, or C” is usedin the claims, it is intended that the phrase be interpreted to meanthat A alone may be present in an embodiment, B alone may be present inan embodiment, C alone may be present in an embodiment, or that anycombination of the elements A, B and C may be present in a singleembodiment; for example, A and B, A and C, B and C, or A and B and C.Different cross-hatching is used throughout the figures to denotedifferent parts but not necessarily to denote the same or differentmaterials.

Systems, methods and apparatus are provided herein. In the detaileddescription herein, references to “one embodiment”, “an embodiment”, “anexample embodiment”, etc., indicate that the embodiment described mayinclude a particular feature, structure, or characteristic, but everyembodiment may not necessarily include the particular feature,structure, or characteristic. Moreover, such phrases are not necessarilyreferring to the same embodiment. Further, when a particular feature,structure, or characteristic is described in connection with anembodiment, it is submitted that it is within the knowledge of oneskilled in the art to affect such feature, structure, or characteristicin connection with other embodiments whether or not explicitlydescribed. After reading the description, it will be apparent to oneskilled in the relevant art(s) how to implement the disclosure inalternative embodiments.

Furthermore, no element, component, or method step in the presentdisclosure is intended to be dedicated to the public regardless ofwhether the element, component, or method step is explicitly recited inthe claims. No claim element is intended to invoke 35 U.S.C. 112(f)unless the element is expressly recited using the phrase “means for.” Asused herein, the terms “comprises”, “comprising”, or any other variationthereof, are intended to cover a non-exclusive inclusion, such that aprocess, method, article, or apparatus that comprises a list of elementsdoes not include only those elements but may include other elements notexpressly listed or inherent to such process, method, article, orapparatus.

What is claimed is:
 1. A fuel flow control system for a gas turbine engine, the fuel flow control system comprising: a fuel supply; a fluid conduit in fluid communication with the fuel supply; an engine control device in fluid communication with the fuel supply; a densimeter operably coupled to the fluid conduit; a first temperature sensor operably coupled to the fluid conduit; a fuel nozzle in fluid communication with the fuel supply; and a second temperature sensor disposed between the fuel nozzle and the fuel supply.
 2. The fuel flow control system of claim 1, wherein the fluid conduit is disposed between the fuel supply and the engine control device.
 3. The fuel flow control system of claim 2, wherein the densimeter is electrically coupled to the engine control device.
 4. The fuel flow control system of claim 1, further comprising a fuel valve assembly, wherein the second temperature sensor is disposed in the fuel valve assembly.
 5. The fuel flow control system of claim 4, wherein the fuel valve assembly includes a fuel valve electrically coupled to the engine control device.
 6. The fuel flow control system of claim 5, wherein the engine control device is configured to modulate the fuel valve based on measurements of the first temperature sensor, the second temperature sensor, and the densimeter. 